Cutter dome for reclaim system

ABSTRACT

A cutter dome for use with a reclaimer includes a sidewall that at least partially encircles a central axis and that extends from a lower end to an upper end, the sidewall having a lower portion that bounds a first chamber and an upper portion that bounds a second chamber, a collection opening being formed on the lower portion of the sidewall so that a reclaimer, such as an auger, can pass through the collection opening and communicate with the first chamber. A roof is disposed on the upper end of the sidewall so as to cover second chamber, the roof having a first inlet formed thereon. A first passageway is disposed within the second chamber and extends from the first inlet to a first outlet, the first outlet communicating with the first chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention relates to cutter domes for use with a reclaimsystem within a storage vessel.

2. The Relevant Technology

Silos are used for storing bulk material such as grains or powders. Thebulk material is typically deposited into the silo through an openingformed at the top of the silo and is removed from the silo through anoutlet centrally formed on the floor the silo. Bottom reclaim systemsare often mounted on the floor of the silo for controlling movement ofthe bulk material to the outlet. The bottom reclaim system includes abase mounted adjacent to the outlet and an auger that outwardly projectsfrom the base. The auger rotates about a central longitudinal axisthereof so as to inwardly draw the bulk material from the perimeter ofthe floor to the outlet. Furthermore, as the auger rotates about itslongitudinal axis, the auger also revolves around the central outlet onthe silo floor. As a result, the auger draws bulk material to the outletfrom all areas on the silo floor.

It is often desirable to have a first-in-first-out (FIFO) inventorycontrol of the bulk material within the silo. This ensures that aportion of the bulk material does not stagnate within the silo. In caseswhere FIFO is important, it is desirable to have the outlet covered sothat the bulk material directly above the outlet does not free flow intothe outlet, thereby precluding FIFO inventory control. A solution tothis problem has been to position a dome on the floor of the silo thatcovers the outlet and the base of the reclaim system. The dome has acylindrical sidewall and a conical roof An opening is formed on thesidewall of the dome through which the auger passes. The auger draws thebulk material through the opening and to the outlet in a controlledmanner. The dome prevents the free-flow of bulk material into theoutlet, thereby helping to ensure the FIFO storage of the bulk material.

The dome, however, introduces other problems. For example, even thoughthe roof of the dome is conical, the bulk material can post on the roofof the dome. In posting, a significant portion of the entire amount ofbulk material within the silo bears its load on a localized region.Specifically, the bulk material can vertically stack on the roof of thedome in a cohesive structure that remains stationary as opposed toflowing out toward the auger. In turn, this stacked bulk material abovethe roof can bridge outward until it eventually reaches the interiorsurface of the silo. In this scenario, large cavities can be producedwithin the silo as the reclaimer removes the freely movable bulkmaterial from below the bridging bulk material.

As a result of the posting of the bulk material on the dome, the domeand reclaimer can be subject to tremendous point-loading caused by thebulk material. That is, whereas the entire weight of the bulk materialis typically uniformly carried over the entire floor of the silo,posting of the bulk material causes the weight of a large percentage ofthe bulk material to be concentrated on the dome. This point loading ofthe bulk material can result in failure of the dome and/or reclaimer.Furthermore, the stacking and bridging of the bulk material and theresulting formation of cavities precludes efficient operation of thereclaimer and prevents FIFO flow of bulk material within the silo. Insome situations, movement of the bulk material within the silo can becompletely stopped. In turn, disrupting the stacked bulk material withinthe silo to restore proper flow of the bulk material can be timeconsuming and dangerous.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention will now be discussed withreference to the appended drawings. It is appreciated that thesedrawings depict only typical embodiments of the invention and aretherefore not to be considered limiting of its scope.

FIG. 1 is a cut away perspective view of a storage vessel housing aninventive reclaim system;

FIG. 2 is an enlarged perspective view of the reclaim system mounted onthe floor of the storage vessel shown in FIG. 1;

FIG. 3 is an enlarged perspective view of the reclaim system shown inFIG. 2 having a cutter dome;

FIG. 4 is a cross sectional side perspective view of the reclaim systemwith cutter dome shown in FIG. 3;

FIG. 5 is a perspective view of an upper portion of the cutter domeshown in FIG. 3;

FIG. 6 is a bottom perspective view of the cutter dome portion shown inFIG. 5;

FIG. 7 is a side perspective view of the cutter dome portion shown inFIG. 5 wherein a portion of the sidewall has been removed;

FIG. 7A is a side view of the flutes of the cutter dome portion shown inFIG. 7;

FIG. 8 is a top perspective view of the reclaim system shown in FIG. 3with a door of the cutter dome in an open position;

FIG. 9 is a top perspective view of the reclaim system shown in FIG. 8wherein the door is in a closed position;

FIG. 10 is a cross sectional side view of the cutter dome with a doorfor the upper dome portion in a partially open position;

FIG. 11 is a side perspective view of an alternative embodiment of acutter dome portion formed of flat flutes wherein a portion of thesidewall is removed;

FIG. 12 is a side perspective view of another alternative embodiment ofa cutter dome portion having radially outwardly projecting inlets;

FIG. 13A is a side perspective view of an alternative embodiment of acutter dome portion having a frusticonical roof portion that slopesradially inward;

FIG. 13B is a side perspective view of alternative embodiment of acutter dome portion having a frusticonical roof portion that slopesradially outward;

FIG. 14 is a cross section side view of an alternative embodiment of areclaim system having a cutter dome with an exposed central shaft andencircling flutes;

FIG. 15 is a top plan view of the reclaim system shown in FIG. 14;

FIG. 16 is a top plan view of the roof of the reclaim system shown inFIG. 14 without the shaft;

FIG. 17 is an alternative embodiment of a reclaim system having afurther alternative embodiment of a dome cutter;

FIG. 18 is a top plan view of the reclaim system shown in FIG. 17;

FIG. 19 is a top plan view of the roof of the cutter dome shown in FIG.17;

FIG. 20 is a cross sectional side perspective view of an alternativeembodiment of a reclaim system having a cutter dome wherein an upperportion of the cutter dome is rotatable independent of a lower portionof the cutter dome;

FIG. 21 is a top perspective view of an alternative embodiment of anupper dome portion with a door in an open position;

FIG. 22 is a top perspective view of the upper dome portion shown inFIG. 21 with the door in a closed position;

FIG. 23 is a bottom perspective view of the upper dome portion shown inFIG. 21 with the door in the open position;

FIG. 24 is a bottom perspective view of the upper dome portion shown inFIG. 23 with the door in the closed position;

FIG. 25 is a bottom plan view of the upper dome portion shown in FIG. 21with the door in the open position; and

FIG. 26 is a bottom plan view of the upper dome portion shown in FIG. 25with the door in the closed position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Depicted in FIG. 1 is one embodiment of a reclaim system 10incorporating features of the present invention and being used inassociation with a storage vessel 12. Storage vessel 12 is shown ascomprising a substantially cylindrical sidewall 14 that extends betweena floor 16 and a cap 18. Storage vessel 12 has an interior surface 20that bounds a compartment 22 that extends between floor 16 and cap 18.An access area 24 is formed below floor 16. Compartment 22 is configuredto receive bulk material. As used in the specification and appendedclaims, the term “bulk material” is broadly intended to include powders,grains, sand, chips, granulated material, and other small diametermaterial that is capable of flowing under the force of gravity. Bulkmaterials typically have an average particle diameter size less thanabout 4 cm, commonly less than about 2 cm, and often less than 1 cm.Common examples of bulk materials include cement, talc, fly ash, salt,chemicals, fertilizers, wood chips, minerals, bauxite, coal, sulfur,beans, grains, such as wheat, barley, corn, oats, and rice, and flourand meal made from beans and grains. A variety of other small diametermaterials can also function as bulk materials.

Storage vessel 12 need not have a cylindrical configuration but can havea variety of different sizes, shapes and configurations. As such,storage vessel 12 can comprise a silo, tank, dome, or any other type ofbuilding structure that bounds a compartment in which bulk material canbe stored. Bulk material is typically fed into compartment 22 through anupper end of storage vessel 12 such as through cap 18 or an upper end ofsidewall 14. This feeding can be accomplished through any conventionalmeans such as conveyor belts, pumps, augers, or the like. As will bediscussed below in greater detail, the bulk material is removed fromcompartment 22 through an opening in floor 16. Reclaim system 10regulates the flow of the bulk material through the opening in floor 16.

As depicted in FIG. 2, reclaim system 10 generally comprises a base 26,a hopper 40, a cutter dome 70, and a reclaimer 180. Base 26 is mountedon floor 16. As depicted in FIG. 3, base 26 has a top side 28 and anopposing bottom side 30. As shown in FIG. 4, base 26 has an interiorsurface 32 that bounds a passage 34 extending therethrough between sides28 and 30. Passage 34 is the opening through which the bulk materialpasses out of compartment 22 of storage vessel 12.

In general, base 26 comprises an outer structure 31 that encirclespassageway 34 and is rigidly secured to floor 16 of storage vessel 12(FIG. 1). Base 26 also includes an inner structure 33 that at leastpartially encircles passageway 34 and is disposed radially inward and/oron top of outer structure 31. Inner structure 33 is movably mounted onouter structure 31 so that inner structure 33 can rotate aboutpassageway 34 relative to outer structure 31. A variety of differentstructures can be formed between inner structure 33 and outer structure31 to facilitate smooth and easy movement of inner structure 33. Forexample, a smooth wear plate, race, or other bearing assembly can beformed between inner structure 33 and outer structure 31. As discussedbelow in greater detail, cutter dome 70 is mounted on inner structure 33of base 26 so that cutter dome 70 can also rotate relative to outerstructure 31 of base 26.

In the embodiment depicted, outer structure 31 of base 26 is comprisedof structural members, such as structural steel, and is mounted on orembedded within floor 16. Floor 16 is typically comprised of reinforcedconcrete. In alternative embodiments, however, outer structure 31 ofbase 26 can simply comprise the portion of floor 16 that surroundspassageway 34 extending through floor 16. Inner structure 33 can then bemovably secured to floor 16.

Mounted on outer structure 31 of base 26 so as to project below floor 16and into access area 24 (FIG. 1) is hopper 40. Hopper 40 has anencircling sidewall 36 with an exterior surface 27 and an interiorsurface 42 that each extend between an upper end 44 and an opposinglower end 46. Interior surface 42 bounds a chamber 48 within hopper 40.An opening 50 is formed at upper end 44 of hopper 40 so that opencommunication is provided between passage 34 of base 26 and chamber 48of hopper 40. Likewise, an opening 52 is formed at lower end 46 ofhopper 40 in communication with chamber 48. As depicted in FIG. 2, doors54 can be mounted at lower end 46 of hopper 40 for selectively openingand closing opening 52. Although not depicted, a conveyor belt, transferpipe, vehicle loading dock, railroad track or other means fortransferring the bulk material away from hopper 40 can be disposed belowdoors 54. As such, when doors 54 are open, bulk material that istransferred into hopper 40 can be deposited on the means fortransferring the bulk material so as to convey the bulk material awayfrom storage vessel 12.

Returning to FIG. 3, rotatably mounted on base 26 is cutter dome 70.Although cutter dome 70 is referred to as a “dome,” this is simply aterm of art and cutter dome 70 need not have a conventional “dome”shaped configuration with an arched roof Rather, cutter dome 70 can havea substantially cylindrical configuration or a variety of otherenclosing configurations. In the embodiment depicted, cutter domecomprises a lower dome portion 72 and an upper dome portion 74. Arotational axis 76, about which cutter dome 70 rotates, centrallyextends down through cutter dome 70.

As depicted in FIG. 4, lower dome portion 72 includes a lower sidewall78 that extends from a lower end 80 to an upper end 82. In the depictedembodiment, lower sidewall 78 has a tubular, cylindrical configurationthat at least partially encircles rotational axis 76. Lower sidewall 78can also have a polygonal, irregular or other configuration. Lower end80 is mounted on inner structure 33 of base 26 so that cutter dome 70rotates about rotational axis 76 concurrently with inner structure 33 ofbase 26. Lower sidewall 78 has an interior surface 84 that bounds afirst chamber 86. An inlet opening 89 is formed at upper end 82 while anoutlet opening 90 is formed at lower end 80. Outlet opening 90communicates with passage 34 of base 26 so that bulk material can passtherebetween.

A collection opening 88 is formed through lower sidewall 78 so thatfluid communication is provided between compartment 22 of storage vessel12 (FIG. 1) and first chamber 86. Collection opening 88 can be formedthrough lower sidewall 78 so that a portion of lower sidewall 78 forms acontinuous loop about rotational axis 76. Alternatively, collectionopening 88 can be formed by forming a gap in lower sidewall 78 so thatlower sidewall 78 has a substantially C-shaped configuration. As will bediscussed below in greater detail, a reclaimer, such as an auger,extends through collection opening 88 for drawing bulk material intofirst chamber 86.

Turning to FIG. 5, upper dome portion 74 comprises an upper sidewall 94that is mounted on upper end 82 (FIG. 4) of lower sidewall 78 and thatextends between a lower end 96 and an upper end 98. Upper sidewall 94has a substantially cylindrical configuration that completely encirclesrotational axis 76. Upper sidewall 94 can also have a polygonal,irregular, or other configuration. As depicted in FIG. 6, upper sidewall94 has an interior surface 100 that bounds a second chamber 102.Returning to FIG. 5, upper end 98 of upper sidewall 94 terminates at aperimeter edge 104. Perimeter edge 104 is comprised of three equal arcedsegments 106A-C each having a substantially identical configuration.Arced segment 106A comprises a top edge 108A that extends from a firstend 110A to an opposing second end 112A. Top edge 108A has a constantradius relative to rotational axis 76 and downwardly slopes from firstend 110A to second end 112A. As a result, first end 110A is positionedhigher along rotational axis 76 than second end 112A.

Arced segment 106A also comprises a shoulder 114A that downwardlyprojects from first end 11A. In one embodiment, shoulder 114A extends ina plane that is parallel to and aligned with rotational axis 76. Inalternative embodiments, shoulder 114A can extend in a plane thatintersects with rotational axis 76 at an angle. Arced segment 106A canbe configured so that an angle θ₁ is formed between top edge 108A andshoulder 114A in a range between about 45° to about 225° with about 65°to about 115° or about 80° to about 110° being more common. Other anglescan also be used. It is also appreciated that shoulder 114A need not bestraight but can also be curved. Arced segments 106B and 106C have thesame configuration as arced segment 106A and are identified by likereference characters. It is noted that the second end 112 of each arcedsegment 106 intersects with shoulder 114 of the adjacent arced segment106.

Centrally disposed within second chamber 102 of upper dome portion 74 isa shaft 120 that extends along rotational axis 76. Upper dome portion 74also comprises a roof 122 that extends between perimeter edge 104 andshaft 120. In the depicted embodiment, roof 122 is comprised of threeequal roof segments 124A-C each having substantially the same circularsegment configuration. Roof segment 124A comprises an inside edge 126Athat is secured to shaft 120, a curved outside edge 128A that extendsalong top edge 108A of perimeter edge 104, a cutting edge 130A thatextends from shaft 120 to first end 110A of top edge 108A, and a backedge 132A that extends from shaft 120 to second end 112A of top edge108A. Because top edge 108A downwardly slopes as previously discussed,outside edge 128A of roof segment 124A has a complimentary slope.Furthermore, roof segment 128A is curved so that inside edge 126A ofroof segment 124A curves along shaft 120 at substantially the same angleas outside edge 128A. This curve is such that if roof segment 124A wasextended, segment 124A would encircle shaft 120 in a downwardlyextending helical configuration.

Roof segments 124B and 124C are similarly mounted so as to extendbetween shaft 120 and top edges 108B and 108C, respectively. As a resultof the height of shoulders 114A-C, elongated inlets 138A-C are formedbetween cutting edge 130 of each roof segment 124 and back edge 132 ofthe adjacent roof segment 124. For example, inlet 138C extends betweenshoulder 114C and shaft 120 between cutting edge 130C and back edge132A. The height of inlet 138C depends on the height of shoulders 114A-Cand the angle at which the roof segments 124A-C are disposed. Inlets138A-C provide fluid communication between compartment 22 of storagevessel 12 (FIG. 1) and second chamber 102 of upper dome portion 74.

As depicted in FIG. 7, disposed within second chamber 102 are threesloped flutes 140A-C. Each flute 140A-C is disposed between shaft 120and upper sidewall 94 and extends from the back edge 132 of acorresponding roof segment 124 to a termination point located above adrop box 142 that is formed within second chamber 102. Each flute 140A-Cdownwardly slopes in a helical path about shaft 120. Furthermore, eachflute 140A-C partially bounds a corresponding passageway 143A-C throughwhich the bulk material travels as it passes from a corresponding inlet138A-C to drop box 142. Each passageway 143A-C also downwardly slopes ina helical path about shaft 120.

Each flute 140A-C slopes down toward drop box 142 so that the bulkmaterial travels downward as cutter dome 70 is rotated. However, flutes140A-C are typically disposed at an angle less than the angle of reposeof the bulk material within compartment 22 of storage vessel 12. Thishelps prevent the bulk material from freely flowing down passageways143A-C. As depicted in FIG. 7A, each flute 140A-C typically slopes at anangle θ₂, which is relative to a plane that is normal to rotational axis76, that is in a range between about 5° to about 30° and more commonlyin a range between about 10° to about 20°. Other ranges can also beused. The bulk material typically has an angle of repose withincompartment 22 that is greater than about 30° relative to thehorizontal.

Returning to FIG. 7, drop box 142 comprises a first partition wall 144that extends along the height of upper sidewall 94, an opposing secondpartition wall 145 that downwardly projects from the terminal end offlute 140C, an outside partition wall 146 that slopes inwardly andextends between the outside ends of partition walls 144 and 145, and aninside partition wall 147 that extends between the inside ends ofpartition walls 144 and 145. The partition walls 144-147 bound an outlet152 that provides fluid communication between first chamber 86 of lowerdome portion 72 (FIG. 4) and second chamber 102 of upper dome portion74. A door 154 (FIG. 10) is hingedly mounted on inside partition wall147 and can be used for selectively opening and closing outlet 152.

As will be discussed below in greater detail, during operation cutterdome 70 is rotated on base 26 about rotational axis 76. As cutter dome70 is rotated, the bulk material sitting on roof 122 passes into inlets138A-C, travels down passageways 143A-C, and passes through outlet 152in drop box 142 into first chamber 86 of lower dome portion 72. The bulkmaterial then travels down through passage 34 in base 26 and intochamber 48 of hopper 40. The fact that inlets 138A-C are positionedbelow cutting edges 130A-C enables cutting edges 130A-C to efficientlycut away at the bulk material as cutter dome 70 is rotated, therebyensuring that the bulk material is fed into passageways 143A-C.

Is appreciated that cutter dome 70 can come in a variety of differentconfigurations. By way of example and not by limitation, in the depictedembodiment upper dome portion 74 is separately formed and secured tolower dome portion 72 such as by bolting, welding, or the like. In analternative embodiment, it is appreciated that the lower sidewall 78 andupper sidewall 94 can be formed from one or more continuous members thatextend the full height of lower sidewall 78 and upper sidewall 94.Likewise, the depicted embodiment includes three inlets 138A-C and threeseparate flutes 140A-C. In alternative embodiments, cutter dome 70 canbe formed from a single inlet 138 and a single flute 140 or,alternatively, from two or four or more inlets 138 and flutes 140.

In still other embodiments, shoulders 114A-C can be eliminated so thatroof 122 is substantially flat. Inlets 138A-C can be formed on flat roof122 leading to passageways 143A-C. In contrast to roof 122 being flat,roof 122 can be conical, domed shaped, semi-spherical or any otherconfiguration. In each of these different configurations, shoulders114A-C can be formed so as to expose cutting edges 130A-C or shoulders114A-C can be eliminated so that inlets 138A-C are formed flat on theroof surface.

Furthermore, in the depicted embodiment flutes 140A-C are secured toroof segments 124A-C such as by welding, bolting or other conventionalmethods. In alternative embodiments, each roof segment 124A-C can beintegrally formed as a unitary member with a corresponding flute 140A-C.Furthermore, each flute 140A-C is shown as only partially encirclingshaft 120. In alternative embodiments, each flute 140A-C can form one ormore complete helical revolutions about shaft 120. Further alternativeembodiments will be discussed below in greater detail.

Returning to FIG. 3, in the depicted embodiment reclaimer 180 comprisesan elongated auger 182 having a first end 184 that is disposed withinthe first chamber 86 and an opposing second end 186 that is disposedoutside of cutter dome 70 but within storage vessel 12. Auger 182comprises a central shaft 188 having a central longitudinal axis 190extending along the length thereof and one or more threads 192 helicallyencircling and extending along the length of shaft 188. Auger 182 passesout of first chamber 86 by passing through collection opening 88.

As depicted in FIG. 4, disposed within chamber 48 of hopper 40 and firstchamber 86 of lower dome portion 72 is a drive train 204. Drive train204 has a first end 205 that is coupled by a belt to a drive motor 206(FIG. 3). Drive train 204 has an opposing second end 208 that is coupledwith first end 184 of auger 182. As such, drive motor 206 and drivetrain 204 facilitate rotation of auger 182 about axis 190 (FIG. 3) whichin turn causes auger 182 to draw the bulk material into collectionopening 88. As depicted in FIG. 20, second end 208 of drive train 204and first end 184 of auger 182 (FIG. 3) are supported by support members210 that extend from inner structure 33 of base 26 to drive train 204.As such, second end 208 of drive train 204 and first end 184 of auger182 rotate concurrently with inner structure 33 of base 26 and cutterdome 70 about rotational axis 76.

As shown in FIG. 3, disposed parallel to and extending along the lengthof auger 182 is a support arm 194. Support arm 194 has a first end 195disposed within first chamber 86 and an opposing second end 197 disposedadjacent to second end 186 of auger 182. Second end 186 of auger 182 isrotatable mounted to second end 197 of support arm 194 to providestructural stability to auger 188. Furthermore, support arm 194 has aninside face 196 having a concave configuration and that extends alongauger 182. Inside face 196 helps to capture bulk material betweenthreads 192 and inside face 196 so that the bulk material is efficientlydrawn down along the length of auger 182 and into collection opening 88.

As better depicted in FIG. 8, a drive shaft 198 is disposed within andextends along the length of support arm 194. Drive shaft 198 is rotatedby a motor 199. Returning to FIG. 3, drive shaft 198 has a distal end201 located at second end 197 of support arm 194. Distal end 201 coupleswith a track, such as through the use of a gear. The track is formed onthe interior surface of 20 of storage vessel 12 adjacent to floor 16 soas to encircle floor 16. Alternatively, the track can be formed on floor16 at the perimeter edge thereof so as to encircle floor 16. Drive shaft198 is engaged with the track so that rotation of drive shaft 198 causesdistal end 210 of drive shaft 198 to slowly move along the length of thetrack. In turn, this movement of drive shaft 198 causes second end 197of support arm 194 and second end 186 of auger 182 to also move alongthe track. In turn, movement of the second end of support arm 194 andauger 182 along the track facilitates the rotation of second end 208 ofdrive train 204, first end 184 of auger 182, inner structure 33 of base26, and cutter dome 70 to concurrently rotate about rotational axis 76.

Reclaimer 180, hopper 40, base 26 and the drive systems disclosed hereincan be purchased from Laidig Systems, Inc. located in Mishawaka,Indiana. In alternative embodiments, it is appreciated that otherconventional reclaimers, hoppers, bases and drive systems can be usedwith the inventive cutter domes of the present invention. For example,in contrast to reclaimer 180 comprising an auger, reclaimer 180 cancomprise different rotating screw configurations, belt conveyors with orwithout paddles, chain conveyors, and other types of continuous draggingor transport systems that are commonly used for movement of bulkmaterial and which could function for moving bulk material into firstchamber 86.

Turning to FIGS. 8 and 9, a door 214 encircles shaft 188 of auger 182and can selectively move along shaft 188. Door 214 is moveable betweenan open position and a closed position. In the open position shown inFIG. 8, door 214 is drawn back from collection opening 88 into firstchamber 86 so that bulk material can be drawn into cutter dome 70through collection opening 88 during rotation of auger 182. In theclosed position shown in FIG. 9, door 214 is moved forward so as toclose off collection opening 88. The closing of collection opening 88through the use of door 214 enables cutter dome 70 and hopper 40 to beemptied of bulk material so that cutter dome 70 and hopper 40 can beaccessed through hopper 40 for maintenance and/or repair of componentstherein. Door 214 is selectively moved between the open and closeposition as a result of a linkage 216 operated by a hydraulic piston218. Linkage 216 used to close door 214 cams over, thereby locking door214 into position in case of hydraulic pressure loss. Other mechanismscan also be used for selectively opening and closing door 214.

Turning to FIG. 10, the opening and closing of door 214 also facilitatesselective opening and closing of door 154 that selectively covers outlet152 of upper dome portion 74. Specifically, as previously discussed,door 154 is hingedly mounted to inside partition wall 147. When door 214is moved to the open position, the force of gravity enables door 154 torotate downward into an open position so that bulk material can passthrough outlet 152. As door 154 is moved to the closed position, a topend 222 of door 214 pushes against door 154 causing it to rotate upwardinto a closed position and thereby close off outlet 152. When door 214is in the close position, top end 222 of door 214 pushes against door154 so as to prevent unwanted opening of door 154. If desired, taperedrams 223 or other structures can be formed at top end 222 of door 214 tohelp facilitate closing of door 154. Again, the closing of door 154 isdesirable so that all the bulk material can be removed from withincutter dome 70 and hopper 40 for accessing the mechanisms therein.

It is appreciated that in alternative embodiments door 154 can be openedusing a variety of different mechanisms such as screw drives, hydraulicpistons or a variety of other conventional systems. As such, doors 154and 214 can be opened and closed separate from each other. The presentdesign, however, elements the need for a second drive mechanism to closedoor 154, ensures concurrent closure of both doors, and provides an easyretrofit of adding an upper dome portion 74 on an existing lower domeportion 72.

During operation, doors 214 and 154 are each moved to the open position.Auger 182 begins to rotate about rotational axis 190 so as to draw thebulk material through collection opening 88 and into first chamber 86 ofcutter dome 70. Simultaneously, cutter dome 70 and auger 182 begin toslowly rotate about rotational axis 76 as a result of the rotation ofdrive shaft 198. Cutter dome 70 and auger 182 typically rotate at a rateof about 1-3 degrees per minute although other rates can also be used.The movement of auger 182 over floor 16 ensures a uniform draw down ofthe bulk material over floor 16 of storage vessel 12. As cutter dome 70is rotated, the bulk material positioned above cutter dome 70 is drawninto inlets 138A-C where it passes down through second chamber 102 andinto first chamber 86 through outlet 152.

The removal of the bulk material from above cutter dome 70 helps tomaintain movement of the bulk material directly above cutter dome 70. Asa result, the bulk material is precluded from setting up or becomingstationary, thereby precluding “posting” or “bridging” of the bulkmaterial above cutter dome 70. Furthermore, the slow rotation of cutterdome 70 controls the material flow such that “rat holing” does notdevelop. Angling the flutes at a angle lower than the angle of repose ofthe bulk material also preclude unwanted free flow of material. Themajority of the bulk material is collected through collection opening88. As a result, the bulk material is primarily processed throughstorage vessel 12 in a first-in-first-out inventory.

Once the bulk material passes into first chamber 86 from eithercollection opening 88 or through cutter dome 70, the bulk material flowsunder the force of gravity through passageway 34 in base 26 and intochamber 48 of hopper 40. The bulk material is then transferred out ofhopper 40 through doors 54 using any conventional means such as trucks,conveyor belts, pumps, or the like.

Depicted in FIG. 11 is an alternative embodiment of an upper domeportion 74A of cutter dome 70. Like elements between upper dome portion74 and 74A are identified by like reference characters. In upper domeportion 74, roof segments 124A-C and flutes 140A-C are bent or contouredso as to extend in a smooth helical path. In upper dome portion 74A,each roof segment 124A-C is comprised of a flat plate in the form of acircular segment that extends from shaft 120 to perimeter edge 104. As aresult, each inlet 138A-C has a substantially triangular configuration.

With regard to flutes 140A-C that extend in a helical path along shaft120, to maintain the helical orientation while maintaining the use ofonly flat plates, the flutes 140A-C are comprised of a series of flatcircular segment plates 230 having a configuration similar to the flatroof segments 124A-C. Each segment plate 230 has an inside edge 234 thatis connected to shaft 120, an opposing arced outside edge 236 thatconnects to sidewall 94, and a first edge 238 and an opposing secondedge 240 extending therebetween. Plates 230 are secured in sequentialorder with outside edges 236 being aligned longitudinally and adjacentinside edges 234 being vertically staggered along shaft 120. Atriangular riser 232 extends between second edge 240 of one plate 230and first edge 238 of the adjacent plate 230, thereby forming a steppedhelical path about shaft 120.

In the upper dome portion 74 depicted in FIG. 5, inlets 138A-C extendedonly along roof 122. In alternative embodiments, upper dome portion 74can also be formed so that the inlets for receiving the bulk materialproject out beyond upper sidewall 94. By way of example and not bylimitation, depicted in FIG. 12 is an alternative embodiment of an upperdome portion 74B of cutter dome 70 where like elements are identified bylike reference characters. In this embodiment, upper sidewall 94 isformed from three sidewall sections 246A-C. Each sidewall section 246extends from a leading edge 248 to a tail edge 250. Each sidewallsection 246A-C radially inwardly curves toward shaft 120 as it extendsbetween ends 248 and 250. As a result, leading end 248 has a radius fromshaft 120 that is greater than the radius between shaft 120 and tailedge 250. As a result of this configuration, inlets 138A-C now outwardlyproject beyond the adjacent sidewall section 246. Furthermore, elongatedinlets 252A-C extends along the length of each sidewall section 246.This inlet again captures bulk material and transfers it into firstchamber 86 as cutter dome 70 is rotated.

In the previous depicted embodiments, inlets 138A-C extended all the wayto upper sidewall 94. In alternative embodiments, however, the inlets138A-C need not extend all the way to sidewall 94. For example, depictedin FIG. 13A is a further embodiment of an upper dome portion 74C ofcutter dome 70 where like elements are identified by like referencecharacters. Upper dome portion 74C includes upper sidewall 94. Howeverroof 122 comprises an outer roof portion 254 and an inner roof portion256. Outer roof portion 254 has a frusticonical configuration thatslopes down and radially inward toward inner roof portion 256. In turn,inner roof portion 256 comprises roof segments 124A-C as previouslydiscussed with regard to upper dome portion 74. In this regard, outerroof 254 functions to funnel bulk materials down to inner roof portion256 which in turn transfers the bulk material to first chamber 86.

Depicted in FIG. 13B is a further alternative embodiment of an upperdome portion 74D. Upper dome portion 74D is substantially the same asupper dome portion 74C except that outer roof portion 254 has beenreplaced with an outer roof portion 258. Outer roof portion 258 also hasa frusticonical configuration but slopes down and away from inner roofportion 256. As a result, outer roof portion 258 facilitates moving thebulk material off of cutter dome 70. In both of the above embodiments,it is appreciated that the inner and outer roof portions can rotateconcurrently with each other and with lower dome portion 72.Alternatively, inner roof portion 256 can rotate independent of theouter roof portion and/or lower dome portion 72. For example, a drivemotor can be used to rotate inner roof portion 256 at a speed greaterthan lower dome portion 72.

Depicted in FIGS. 14 and 15 is an alternative embodiment of a cutterdome 70A wherein like elements are identified by like referencecharacters. Cutter dome 70A comprises lower dome portion 72 and an upperdome portion 74E. Upper dome portion 74E comprises a roof 260 mounted onlower dome portion 72. Roof 260 comprises a circular frusticonicalsidewall 262 that slopes radially inwardly and up to a central recess264. Recess 264 is bounded by a circular sidewall 265 and a floor 266.As depicted in FIG. 16, floor 266 has a pair of openings 268A and Bwhich are selectively opened and closed by doors 270A and B. Althoughnot shown, it is appreciated that openings 268A and B connect bypassageways to drop box 142 (FIG. 7).

Returning to FIG. 14, extending through floor 270 is shaft 120. One ormore flutes 272 are helically formed on the exterior of shaft 120.Flutes 272 projects out so as to be adjacent to sidewall 265 of recess264. As a result, flutes 272 block the free flow of bulk material intoopenings 268A and B. Again, during operation, lower dome portion 72 andupper dome portion 74 can rotate concurrently so that as shaft 120 isrotated, the bulk material passes down along flutes 272 and intoopenings 268A and B. Alternatively, a separate drive motor within lowerdome portion 72 can be used to selectively rotate shaft 120 independentof lower dome portion 72 and roof 260. In an alternative embodiment forcutter dome 70A, it is also appreciated that roof 260 can be configuredsimilar to outer roof portion 254 (FIG. 13A) so that the bulk materialis funneled toward recess 264 as opposed to away from recess 264.

Turning to FIGS. 17-19 is a further alternative embodiment of a cutterdome 70B incorporating features of the present embodiment. Again, likeelements are identified by like reference characters. Cutter dome 70Bcomprises lower dome portions 72 having a roof 280 formed thereon. Roof280 has a pair of openings 282A and B that are selectively opened andclosed by doors 284A and B respectively. Shaft 120 centrally extendsthrough roof 280. A flute 286 is mounted on and helically encircles theexterior surface of shaft 120. A drive mechanism disposed within lowerdome portion 72 facilitates rotation of shaft 120 independent of lowerdome portion 72. With doors 284A and B open, rotation of shaft 120causes the bulk material to travel down the flute and into inlets 282Aand B. The bulk material then passes from inlets 282A and B throughlower dome portion 72 and into hopper 40. Flute 286 is intended toproject out to the edge of roof 280 so as to preclude any posting of thebulk material on roof 280.

In any of the foregoing examples, is appreciated that upper dome portion74 can rotate independent of lower dome portion 72. That is, upper domeportion 74 can rotate at a different speed than lower dome portion 72.Depicted in FIG. 20 is one embodiment of how to facilitate such movementbetween dome portions 72 and 74. In this embodiment, upper dome portion74 connects within lower dome portion 72 on a track 290. Track 290permits rotation of upper dome portion 74 relative to lower dome portion72 and can comprise a smooth wear plate, race, bearing assembly or thelike. An annular engagement track 292 is disposed on the interiorsurface of upper dome portion 74 having a plurality of teeth 294 formedthereon. A gear 296 engages teeth 294. A drive assembly 298 rotates gear296 which in turn facilitates rotation of upper dome portion 74 relativeto lower dome portion 72. In turn, however, lower dome portion 72 anddrive assembly 298 rotate relative to outer structure 31 of base 26.Depicted in FIGS. 21-26 is a further alternative embodiment of an upperdome portion 310 incorporating features of the present invention. Upperdome portion 310 is similar to upper dome portion 74 shown in FIGS. 5-7and like elements are identified by like reference numbers. It is notedthat part of the upper sidewall 94 of upper dome portion 310 is removedto help show the internal structure.

Similar to upper dome portion 74, upper dome portion 310 is shown havingthree roof segments 124A-C and three inlets 138A-C. However, in contrastto upper dome portion 74 wherein all three of passageways 143 terminateat a common outlet 152, upper dome portion 310, as shown in FIG. 21,includes three flutes 312A-C leading from corresponding inlets 138A-C,respectively. Each flute 312 A-C extends a short distance in a downward,helical path about shaft 120 and terminates, as shown in FIG. 23, at aseparate outlet 316A-C, respectively. That is, each flute 312A-C whichpartially bounds a corresponding passageway 314A-C terminates at aseparate, isolated outlet 316A-C. Each outlet 316A-C is shown having awedge shaped configuration and downwardly communicates with firstchamber 86 of lower dome portion 72 (FIG. 4). Because passageways 314A-Care shorter than the passageways of upper dome portion 74 and each exitsthrough its own outlet 316A-C, there is less chance of bulk materialclogging within upper dome portion 310.

As with upper dome portion 74, however, it is desirable to be able toselectively close outlets 316A-C so that lower dome portion 72 can beaccessed without risk of being trapped by the bulk material. To thatend, a door 318 is mounted within second chamber 102 below outlets316A-C. Door 318 is shown in the form of a circular plate having threeopenings 319A-C. Each opening 319A-C has a wedge shaped configurationcomplementary to outlets 316A-C. Door 318 centrally rotates about shaft120 and is movably supported around it perimeter edge by supports 320secured to upper sidewall 94. A beam 336 is shown spanning betweenopposing sides of upper sidewall 94 and supports shaft 120.

As shown in FIGS. 25 and 26, door 318 is moved by an actuator 322.Actuator 322 includes a body 324 having a first end 328 hingedly mountedto upper sidewall 94 and an opposing second end 330. A piston 326 has afirst end 332 slidably mounted within second end 330 of body 324 and anopposing second 334 hingedly mounted to a bottom surface of door 318. Inone embodiment, actuator 322 can comprise a pneumatic or hydraulicpiston. In other embodiment, actuator 322 can comprise a screw drive orany other actuator that can expand and contract.

Actuator 322 and door 318 are movable between an open and closedposition. In the open position as shown in FIGS. 21, 23, and 25,openings 319A-C on door 318 (FIG. 23) are aligned with outlets 316A-C,respectively, so that the bulk material can freely flow out throughoutlets 316A-C and into first chamber 86. Upon actuation of actuator322, piston 326 advances out of body 324, thereby causing door 318 torotate so that door 318 covers outlets 31 6A-C and thereby blocks theflow of bulk material out of outlets 31 6A-C, as shown in FIGS. 22, 24,and 26. Outlets 316A-C can thus be selectively opened and closed byrotating door 318 back and forth through the use of actuator 322.

As discussed above with regard to upper dome portion 74, it isappreciated that upper dome portion 310 can be formed with one, two, orfour or more inlets 138 and corresponding outlets 316. Likewise, outlets316 and openings 319 can be any number of different configurations aslong as door 318 can selectively open and close outlets 316.Furthermore, single door 318 can be replaced with a separate door foreach outlet 316. These doors can slide horizontally or pivot similar todoor 154 (FIG. 10) to selectively open and close the separate outlets316. A separate actuator can be used with each door.

The cutter domes disclosed herein solve the problem of eliminating (orgreatly reducing) the risk of material posting at the center of thestorage vessel, while at the same time prevent the unwanted free-flow ofbulk material out of the storage vessel, thereby ensuringfirst-in-first-out (FIFO) reclamation of stored bulk material. It isappreciated that the different disclosed embodiments of the cutter domeare merely examples of the inventive cutter dome and that otherembodiments can also be used. For example, different features of thedifferent cutter domes can be mixed and matched to produce otherembodiments. Furthermore, a variety of different reclaimers, hoppers,bases and drive assemblies can be used with the inventive cutter domes.It is also noted that the inventive cutter domes can be formed as partof a new reclaim system or can be retrofitted onto an existing reclaimsystem.

Accordingly, the present invention may be embodied in other specificforms without departing from its spirit or essential characteristics.The described embodiments are to be considered in all respects only asillustrative and not restrictive. The scope of the invention is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes which come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

1. A reclaimer system comprising: a base having a passage extendingtherethrough; a cutter dome having a rotational axis, the cutter domebeing mounted on the base so that the cutter dome can rotate relative toat least a portion of the base about the rotational axis, the cutterdome comprising: a sidewall that at least partially encircles therotational axis and that extends from a lower end to an upper end, thesidewall having a lower portion that bounds a first chamber and an upperportion that bounds a second chamber, a collection opening being formedon the lower portion of the sidewall and communicating with the firstchamber; a roof disposed on the upper end of the sidewall so as to coverthe second chamber, the roof having a first inlet formed thereon; and afirst passageway disposed within the second chamber and having a helicalconfiguration that extends from the first inlet on the roof to a firstoutlet that communicates with the first chamber; a reclaimer having afirst end disposed within the first chamber of the cutter dome and anopposing second end disposed outside of the cutter dome, the reclaimerpassing through the collection opening.
 2. The reclaimer system asrecited in claim 1, further comprising: a second inlet formed on theroof; and a second passageway disposed within the second chamber andextending from the second inlet to a second outlet, the second outletcommunicating with the first chamber.
 3. The reclaimer system as recitedin claim 1, wherein the sidewall has an exterior surface with asubstantially cylindrical configuration.
 4. The reclaimer system asrecited in claim 1, wherein the upper portion and the lower portion ofthe sidewall are fixed relative to each other.
 5. The reclaimer systemas recited in claim 1, wherein the roof comprises a first roof segmentcomprising a first inside edge disposed toward the rotational axis and afirst outside edge disposed toward the sidewall, the first inside edgeand the first outside edge each extending between a first cutting edgeand a first back edge, the first roof segment being sloped relative tothe rotational axis so that the first cutting edge is disposed higher onthe rotational axis then the first back edge.
 6. The reclaimer system asrecited in claim 1, wherein the roof comprises: a first roof segmentcomprising a first inside edge and a first outside edge each extendingbetween a first cutting edge and a first back edge, the first insideedge extending about the rotational axis in a helical path so that thefirst cutting edge is disposed higher on the rotational axis then thefirst back edge; and a second roof segment comprising a second insideedge and a second outside edge each extending between a second cuttingedge and a second back edge, the second inside edge extending about therotational axis in a helical path so that second cutting edge isdisposed higher on the rotational axis then the second back edge, thefirst inlet being bounded between the first cutting edge and the secondback edge.
 7. The reclaimer system as recited in claim 1, furthercomprising a door configured to selectively open and close the firstoutlet that communicates between the first chamber and the secondchamber.
 8. The reclaimer system as recited in claim 7, wherein the doorrotates about the rotational axis when moving between opening andclosing the first outlet.
 9. The reclaimer system as recited in claim 1,further comprising a hopper mounted to the base, the hopper having achamber that communicates with the first chamber in the cutter domethrough the passage in the base.
 10. The reclaimer system as recited inclaim 1, wherein the upper portion of the sidewall is rotatably mountedon the lower portion of the sidewall so that the upper portion of thesidewall, roof, and first passageway can concurrently rotate about therotational axis relative the lower portion of the sidewall.
 11. Thereclaimer system as recited in claim 1, further comprising a first flutedisposed within second chamber, the first flute at least partiallyencircling the rotational axis in a helical path and at least partiallybounding the entire length of the first passageway.
 12. The reclaimersystem as recited in claim 11, further comprising: a second inlet formedon the roof; and a second flute disposed within second chamber, thesecond flute at least partially encircling the rotational axis in ahelical path and at least partially bounding a second passageway thatextends from the second inlet on the roof to the first outlet thatcommunicates with the first chamber.
 13. The reclaimer system as recitedin claim 11, wherein the sidewall is mounted on the base so that thesidewall, roof, and first flute can concurrently rotate relative to atleast a portion of the base, the passage of the base communicating withthe first chamber.
 14. The reclaimer system as recited in claim 11,further comprising a shaft disposed along the rotational axis, the firstflute being secured to the shaft so as to at least partially encirclethe shaft in the helical path.
 15. The reclaimer system as recited inclaim 1, further comprising: a first door configured to selectively openand close the collection opening; and a second door configured toselectively open and close the outlet that communicates between thefirst chamber and the second chamber.
 16. The reclaimer system asrecited in claim 1, wherein the reclaimer comprises an auger.
 17. Thereclaimer system as recited in claim 1, further comprising: second inletformed on the roof; a second passageway disposed within the secondchamber that extends from the second inlet on the roof to a secondoutlet that communicates with the first chamber; and a door that opensand closes the first passageway and the second passageway.
 18. Thereclaimer system as recited in claim 1, wherein the first passagewayhaving the helical configuration at least partially encircles therotational axis.
 19. A reclaimer system comprising: a cutter dome havinga rotational axis, the cutter dome comprising: a sidewall that at leastpartially encircles the rotational axis and that extends from a lowerend to an upper end, the sidewall bounding a chamber, a collectionopening being formed on the sidewall and communicating with the chamber;and a roof mounted on the upper end of the sidewall, the roof having afirst inlet formed thereon; and a shaft projecting from the roof; and afirst flute secured to and at least partially encircling the shaft in ahelical configuration so that the first flute bounds a helical path, thehelical path communicating with the first inlet on the roof; and areclaimer having a first end disposed within the chamber of the cutterdome and an opposing second end disposed outside of the cutter dome, thereclaimer passing through the collection opening.
 20. The reclaimersystem as recited in claim 19, wherein the shaft outwardly projectsabove the roof and the flute extends radially outward from the shaft soas to cover the first inlet on the roof.
 21. The reclaimer system asrecited in claim 19, wherein the reclaimer comprises an auger.
 22. Thereclaimer system as recited in claim 19, wherein the first flutecompletely encircles the shaft in a helical configuration.
 23. Areclaimer system comprising: a base having a passage extendingtherethrough; a cutter dome having a rotational axis, the cutter domebeing mounted on the base so that the cutter dome can rotate relative toat least a portion of the base about the rotational axis, the cutterdome comprising: a sidewall that at least partially encircles therotational axis and that extends from a lower end to an upper end, thesidewall having a lower portion that bounds a first chamber and an upperportion that bounds a second chamber, a collection opening being formedon the lower portion of the sidewall and communicating with the firstchamber; a roof disposed on the upper end of the sidewall so as to coverthe second chamber, the roof having a first inlet formed thereon, theroof comprising a first roof segment comprising a first inside edgedisposed toward the rotational axis and a first outside edge disposedtoward the sidewall, the first inside edge and the first outside edgeeach extending between a first cutting edge and a first back edge, thefirst roof segment being sloped relative to the rotational axis so thatthe first cutting edge is disposed higher on the rotational axis thenthe first back edge; and a first passageway disposed within the secondchamber that extends from the first inlet on the roof to a first outletthat communicates with the first chamber; a reclaimer having a first enddisposed within the first chamber of the cutter dome and an opposingsecond end disposed outside of the cutter dome, the reclaimer passingthrough the collection opening.
 24. A reclaimer system comprising: abase having a passage extending therethrough; a cutter dome having arotational axis, the cutter dome being mounted on the base so that thecutter dome can rotate relative to at least a portion of the base aboutthe rotational axis, the cutter dome comprising: a sidewall that atleast partially encircles the rotational axis and that extends from alower end to an upper end, the sidewall having a lower portion thatbounds a first chamber and an upper portion that bounds a secondchamber, a collection opening being formed on the lower portion of thesidewall and communicating with the first chamber; a roof disposed onthe upper end of the sidewall so as to cover the second chamber, theroof having a first inlet formed thereon; a first passageway disposedwithin the second chamber that extends from the first inlet on the roofto a first outlet that communicates with the first chamber; a first doorconfigured to selectively open and close the collection opening; and asecond door configured to selectively open and close the first outletthat communicates between the first chamber and the second chamber; areclaimer having a first end disposed within the first chamber of thecutter dome and an opposing second end disposed outside of the cutterdome, the reclaimer passing through the collection opening.